Means for forming filamentary articles



Nov. 1l, 1952' A. o. RYAN MEANS FOR FORMING FILAMENTARY ARTICLES Filed Sept. 7, 1950 M. R. m@ N I7 Patentecl Nov. Il', 1.952

UNITED STA-TES OFFICE 2,617,148 MEANS FR FORMING FILAMENTARY ARTICLES llert" O` Ryan', Norwalk, Conn., assigner t6 Re'd ding Manufacturing Company, Inc.; Norwalk," Conn., a corporation of Delaware Appucati'onseptember 7, 1950,y serial No. 183,597

Claims. (ci. 1st-si This iiiieiiiioii ieiiiei iii nifiiiii foiiniia iiiiiiirtsi-iaith @ifi `iiieiiiiiiii..patiti?.iii ha lamentary articlsardgnore particularly, to api vary greatly, as for eigample from.5 to 1-0iorl 20 or paratus for the continuous' forliatfion' of threadieven 4`f feet and depends upon the time required' like structures from liquids tvhili may be hardto oagulate the larnentfornnng Il uid. ened by a change temperature, or by' physical 5 tube portionlg? s lj'ould have a cross-SenfA or chemicalreaction.- "Irli'isf application isa 4con'- tionalshape orrespondingproportionallyto* the tinuation-in-Dart of oopeding application Serial cross-sectional Shapedslj'ed of the figlshedlaf No. 677,9 2, tiled June 2'0Q1f94`6`, now abandoned,v :nent rsincelitl giveshshap to;th e str earn o fonwhich wasv a division of copend'ing applioation fin'ingili'quid Whieh is par ofthellainentfornij semaine. 491,476g1ed`Jnei1'9, ieiianow Patent 10 mgl apparatus and 1 tnrougntupe Aiti No. 2,402,846. before the filament -forming;I liquidisintroduoed, An object of thisiventionis to proviuemeans and which serves to ta'nsi'ntgtheergssPseQtiQnal for forming lamentary articles of high,v uniform shape of the tube lto the Iilanient: forming quality. l stream and the'res'ult'ingllalment A Zasthey ad- Another object of this invention'is toprovide 15 vaf iillolgffllqrlfl0111v- I Qi lQher-WTIS means for continuously foriningthreadsof uni- Cpilllng liquid 46 1S ihusan ltI I1 I1l2 0 f n the aD- form cross sectionl from-coagulableor solidiable' paratus-employedffofforniing-the lainent liquidthe. .eiiibdiiiii'ii 0f .ihelliiiifeiitieitshiiwiig Another object of this'i inventionis'to providel lfiereir1 'the chafr'rilgeiul I Zandtlie tune maare lled means for continuously forming threadsof pre- 20 With aiilillg I llirfo, s uiablefgr tf1? liquid determined shape. material to becoagulatedor solidified, andfvvhioh A further object of tlis invention is to provide sialngd glider Constant pressure through means for continuously forming threads of laih lt pipi? I4 from ai C 0 1l 3ai11 r 2 2 -WhlissuQv mentsA without longitudinaltension; plied tffinfthe (irlilit 2 4. ln order to maintain; An additionai objector thisinvention isf tof 25 a Constant Read' Within the; iOsIitniil" 22@ the. provide apparatus-includingiasan'elementthereof latte-V11A may belfrined Wtliizan-overllowlpipe; 2 6

Aspecine object of this-'invention isdireetedfw means-gf @pump 311 supplied froii'ithe surrpl 12., novel means` for' producingelatex threadv if desired itsY temperature maybe ontrplled by Tneseand other obje-cts and advantages' of the means' litanysuitablefapnaratus imitated at' 322g following descriptiony of ai preferredil eXamp1e'f35 ef lallnflfilllng" isV supplied Figure 1 isa^scliematic"view; witlii'ce'rta'in" por? AVOKZZ'Q', Bc'n'hl-ghiksbho' invention; may be accurately controlled, the coritaint'srL 3ft Figure 2 isan` enlarged;partial icrossfsectio'nal may bfSUflJ-ddby $P I `,1g M ;Which l is. ,S0` View of part-of the apparatus illustrated iii-Fig:- desigrledhat as the lilarnent forming material ure 1; leaves the; @Qnlaieerfittii'sssriig.4l ,Will ein: Figure 3 is a transverse cross-seetiona-l-i View' 45 tra@ S1161;v @in amlmtas tQ keep thehead l of the taken along` the line-3---3Y offFigure 2; and lid-11191 upplycopstant. Lfikew'isegdas -Inore liquid Fig-ure- 4 is i a-4 transverse cross-sectionaii vievvI is ?idde F0 the (,gntilflf 34 flfom; time 159 time. showing a modiiediformi' of'i'the apparatusillusY` the Splilgii will Qlgarld S935 tqrllaiflan `the trated in Figure 2. head in this container gonstantrelativels'i` to thev In the example"illustrated` in FigureJ 1,` there is 50 p-SOQO #11QQZ-f-f ,j shown along tube Ill which may loe-formedof Inth'e elnbodiinentrofthe invention shown in' iihloiiehout'its lengthiiridito'itsdisiihiilieiieiid;v 55 Polrlslfllgr; .likll' s andthe larger portion lf2. The-innerdiameter of-f any; sutabledevicefor alteringy the -heightofy the Sadportion 'la ofthe tubel isverv srina'llfiorrr-` resfiYQfwhlekeeniris the heeel; 0f liguidfat' apared to its length, and 0n the order 0f 1A, of an fixed level therein, or'keeping the reservoir position fixed and altering the utilizing a closed reservoir with a device for maintaining a fixed level therein and applying a pneuliquid level therein, or

matic pressure above the liquid surface which can be controlled at will. Replenishrnent of the filanient forming material must be accomplished manually or automatically in each case except for the closed system wherein it must be done automatically in conjunction with a level control device or instrument. Another method to control the flow rate consists of a flow resisting unit or valve. These are generally too costly and unsatisfactory when the filament forming material is natural rubber latex.

The fiow resisting element in the filament forming liquid conduit shown in Figure 1 consists of the nozzle IS the length of which may desirably be from 1 to e inches and the bore of which may desirably be from .020 to .080 inch depending upon the size of the mono-filament desired.

The function of the confining liquid lli) as part of the apparatus is in no noticeable way altered or affected by the movement of the thread forming material through tube Illa. rfhe ratio of area of the filament at the center to the crosssectional area of the conduit, taking for illustration the cross-sectional area of V8 inch which I have usually and successfully employed, is 1 to 17.6 or about 5.7%.

The flow rate of the filament forming material depends largely upon the difference in hydraulic pressure at the inlet to nozzle I6 and the hydraulic pressure of the confining liquid at the exit end of said nozzle, which is the point where the filament enters and is enveloped by the confining liquid, and by varying either pressure the ow rate will vary accordingly. Thus the pressure on the confining liquid governs the speed of lament formation, and the differential pressure of the filament forming liquid relative to the confining liquid pressure controls the filament size. The shape of the filament is controlled solely by the shape of the conduit which is fixed, this shape being transmitted to the filament by the confining liquid 4B.

In the application of the apparatus for filament forming it will be understood that confining liquid 4i] is caused to fiow from the container 22, and fill the chamber l2 and then flow into and through the tube portion 10a to the sump 28. The tube portion lila must be completely full of the confining liquid throughout its length before the lament forming operation is started. With confining liquid MJ flowing through tube portion tile, the filament forming liquid to be coagulated or solidified is supplied from the container 34 and fiows through the nozzle l5 and is then discharged from the end of the nozzle into the moving stream of confining liquid near the entrance end of tube portion lila. In employing the apparatus disclosed herein it is contemplated that the relative pressures of the two liquids in the containers 34 and 22 are such that, as they merge in the chamber l2, preferably just ahead of the entrance to the tube portion Ilia, the two will flow as a single fluid with viscous flow, that is to say, the confining liquid 40 fiowing with viscous flow will have its relative velocity slowest at its outer periphery where there is frictional contact with the wall of tube llla and fastest at its center, and the filament forming liquid and the resulting filament 42 will flow at the speed of the center of the confining liquid (Figure 2). Thus both liquids will have substantially the same speed at their interface. The liquid to be coagulated or solidified will move along in the center of the conning liquid stream 40 as a continuous enclosed thread-like form which gradually coagulates or solidifies into a solid continuous filament I2. This solid thread or filament passes out from the exit end of the tube portion l without any substantial 1ongitudinal tension having been exerted on it during the forming and hardening steps and may then be passed, as for example over roller 44, to a suitable cooling and washing bath (not shown).

This viscous flow of confining liquid ri and the filament forming liquid not only prevents the mutual diffusion of miscible liquids or the mixing of non-miscible liquids of low viscosities but it is essential for achieving the object of providing laments of improved quality in that they are of substantially uniform cross-section and of predetermined shape. Irrespective of the discharge speed of the filament forming liquid from the nozzle l the two liquids move together through the tube portion 16a without subjecting the filament forming material to tension while it is being coagulated or solidified.

Viscous flow in conduits is controlled by the physical dimensions of the conduit and the characteristics of the liquid. For this reason it becomes necessary to consider the liquid as a part of the apparatus. The relationship necessary to maintain viscous flow is expressed mathematically by the Reynolds number which is a dimensionless factor indicating the relationship between the physical dimensions of the conduit and the characteristics of the fluid necessary to maintain viscous flow. The Reynolds number is determined by the formula DVd where D is the diameter of the conduit, V is the velocity, d is the density and o is the viscosity of the fluid. Furthermore, the fluid velocity V through the conduit depends in turn upon the inlet and outlet pressures or, preferably stated, the pressure drop within the conduit and the resistance to flow of the fluid which depends upon the internal diameter of the conduit and its length together with the viscosity or the fluid. Referring to the drawing, the flow rate through the filament forming tube lila depends upon the pressure of the confining liquid 40 in the chamber l2 which is the entrance to the tube 10a, and the pressure at the exit end of tube IllaL which is nil. This differential pressure is the motive force causing fiow through the tube la. The wall of tube lila offers resistance to flow depending upon its internal diameter, its length, and the viscosity of the confining fiuid 40. With the dimensions of tube I0EL fixed, and the viscosity of the fluid fixed by controlling the temperature, the only remaining variable to control in order to control the iiow rate is the pressure of the confining fluid 4B, which is controlled by the liquid head or its equivalent as explained above.

The control of the flow rate is desirable to provide first, viscous flow of the confining fluid d, and, second, flexibility in maintaining the desirable velocity through the tube ItaL which is necessary, in conjunction with the length of the conduit 10a, to establish the time element necessary to allow for the transition of the filament forming liquid to a solid filament while moving continuously and without tension in a space where the shape of the conduit is transmitted to the filament through the confining liquid (see Figures 3 and 4).

The apparatus is applicable for producing threads of any cross-sectional shape, provided only that the inner cross-sectional area of the tube lila is small and shaped proportionately to the cross-section of the desired thread. In Figure 4, for example, I Ahave shown on an exaggerated scale, a flat thread |42 in a stream |40 of confining liquid contained within a tube I0. The filament forming portion of tube H0 is so proportioned that the speed of the central` area of the stream of confining liquid whichr surrounds the thread |42 is constant and the same as the discharge speed of the lament forming material from the nozzle I6. As will be seen from a study of Figure 2', by way of comparison, this constant area of core of the stream of confining liquid will al-waysfbe found equally spaced from the inner walls ofi the container. Thus, if the constant speedV core is to have an irregular cross-section, the inner walls of the container must have substantially similar shape. Other forms of thread than that shown in Figures 2, 3, and 4, are, of course,

shaped proportionately to the cross-section of the desired thread form.

The limitation of dimensions governing the use of this apparatus is determined by selection of practical values. The tube l0a has two critical dimensions, internal diameter and length. The length of this tube is governed by the material and size of the filament being formed and is indicated by the time in seconds necessary to transform thev liquid into a solid filament of sufficient rigidity to prevent deformation under the operating conditions. In the case of natural rubber latex compounds the tube Hl may be as short as 2 or' 3 feet, whereas combinations of materials requiring more time may require tube lengths up to l0y feet or more and relative slow velocities of flow. Since the pressure drop in tube I0a is proportional to its length, this pressure drop may be a limiting factor. However, the increased pressure drop can be offset by increasing the internal diameter of a tube |0a within the operative range of diameters.

The inside diameter is selected to provide a suitable practical balance between the flow rate, viscosity of the confining liquid and the pressure drop. The lower limit is controlled only by the ability to keep the tube clean. In the formation of latex rubber threads a ,-l inch tube has been used on the finerA sizes, 100 to 200 gage.

For larger sizes of filament, pages 37-50, sizes up to 1A inch have been successfully employed. However, 1A; inch diameter isthe most lpractical size when the viscosity of the confining liquid is about 35 centipoises.

I have found that, for forming filaments from materials now available, tubes having an internal diameter on the order of from al.; to 1A; inch are desirable, where the tube is of circular cross sections. For best results in forming a round thread, it is desirable that the interfacial tension be as high as possible., but surface tension is not the controlling factor. For shapes other than circular the diameter may be calculated by figuring that-itisV equal where the ow is known given by way and not" for limitation:

the Reynolds value ing speed (preferably in the range of 500 to 1000 feet/min), gives a Reynolds value below 2100.00.

2. As a second example I will mention a relationship which is unsatisfactory. If water, which has a viscosity Value of 1.0 centipoise, is utilized as the confining liquid in a tube |0001c 0.125 inch I. D., the apparatus thus provided is unsatisfactory for nlament forming because the Reynolds value of this combination is 9700 which is in excess of 2100, the top of the critical range for viscous flow, and the flow of the confining liquid 40' in tube I0a isturbulent preventingthev desired condition of filament formation free from tension. l

3. As a third example I will indicate how a desiredlow rate may be obtained or maintained of the confining liquid 22nd ed., p. 819, and assuming a vertical tube.

|0a, is as follows:

fd [Le (d sin@ IMU therefore Where wzweight rate of flow lbs/second D=diameter in feet drdensity (lbs/cu. ft.) gc=accel. due to gravity=32.2 ft./sec.2 vzabsolute viscosity lbs. (mass) (ft.) (seconds) azangle between conduit axis and horizontal- P1Pz=upstream andV downstream pressure lbs./

Lrlength 'of conduit. I0a

thread was formed at the rate thus w'ell within they As another example of apparatus successfully employed in carrying out my invention, it may be mentioned that a tube having an internal diameter of one-eighth of an inch, and with confining liquid fiovving therethrough With viscous flow, has been employed in forming thread .027-.0067 of an inch in diameter.

There are numerous liquids available which may be employed as the confining liquid 4H, and the choice will depend on two or more factors, including cost, viscosity, hydroscopicity, tendency for changes in properties with change in temperature, ease of removal from filament, corrosiveness, health hazards etc. Among the liquids I have found satisfactory to use as the confining liquid are: Water thickened with carboxy methyl cellulose derivative; acid solutions thickened with a suitable thickeningr agent; salt solutions; glycerine; glycols; glycerine derivatives; castor oil; higher alcohols etc. 'Ihe only primary requirement is that the viscosity of the confining liquid is such that in a tube of a given small diameter, and at a given pressure it will flow with viscous flow. This requirement is essential to its function as part of the equipment for filament forming and is independent of the other elements of the apparatus.

A secondary requirement depends upon its function as a part of the process for which my apparatus is intended, and, as such, is dependent upon the type of material being hardened and the nature of the changes resulting in this hardening. Natural rubber latex compounds are very quickly coagulated by acids, salts, and, if sensitized, by heat, and, the apparatus for forming laments from such compounds must include a confining liquid, which, in addition to being viscous, must contain either an acid, or salts, or both, or be heated to a temperature high enough to result in heat coagulation of the filament.

Synthetic rubber or resin latices, except in rare instances, are not coagulable by acids. Instead they are sensitized to concentrated salt solutions and to freezing. Almost no other methods are now available for coagulating them. Even under optimum conditions the coagulation rate is slow and the tube ma must be very long, and, in addition to being viscous, the salt concentration must be very high. Sometimes, this concentration is suiciently high to require a reduction in viscosity which may be accomplished, for example, by the addition of a suitable alcohol.

In those cases where freezing is the only satisfactory method of coagulation, refrigerated liquids of suitable viscosity may be used. Generally the viscosity will be excessive and must be reduced in a suitable manner. The temperature selected Will depend upon the heat transfer rate and the effect on viscosity.

In general, once has been determined for the material to be coagulated, the only requirement needed to make it function as part of the equipment is to adjust and maintain the viscosity at a suitable value. When this is done, no other changes are necessary. Replenishment of the material lost is the only requirement thereafter.

The application of the apparatus for the formation of threads from a variety of materials is contemplated. For example, artificial threadforming resins or plastics may be discharged into a moving stream of material and there condensed, polymerized or chemically interacted, as the case may be. Likewise, with similar suitable a suitable confining liquid.

apparatus, molten metal may be discharged into a stream of cooling material and carried therealong until it becomes suitably hardened for Withdrawal. It will thus be apparent that, in accordance with the principles of my invention, substantially any temperature-hardenable or chemically-hardenable material may be used, pro vided it is confined and shaped Within a suitable medium flowing With viscous flow and therefore free of longitudinal tension; a temperature-hardenable liquid may be defined as any liquid, solution or colloid Which is in a normally liquid state but which would become hardened or coagulated at an elevated temperature, or, to put it more simply, any liquid which can be changed to a substantially permanent hardened condition by a temperature elevation or depression.

My apparatus may be employed for forming filaments from plastisols which contain thermoplastic resins dispersed in a plasticizer. They may be converted into a continuous filament in my apparatus by exposure to sufficiently high temperature for a suitable time. It is essential, when employing plastisols as the filament forming material, to use a non-miscible liquid with a suitable viscosity at the temperature employed. Molten alloys can be formed in this apparatus by utilizing as an element of the apparatus a confining liquid of suitable viscosity at the temperature needed to solidify the metal iilaments.

In the manufacture of artificial textile laments many starting solutions cannot be quickly and continuously converted into a lament sufciently strong to support themselves.

-In some cases, as for example when using a protein solution as the filament forming material, the solution is coagulated with an acid and hardened with formaldehyde, and a thickening agent is employed to obtain and maintain the suitable viscosity. For the formation of textile filaments from some special solutions, diffusion of the solvent or dilution of the solvent will result in coagulation of the solvents. Diffusion processes are almost, Without exception, very slow, and, my apparatus, employing a suitable confining liquid, is Well adapted to provide suficient time for conversion of the liquid to a solid filament.

It will thus be seen that there has been provided by this invention an apparatus in which the various objects hereinabove set forth together with many thoroughly practical advantages are successfully achieved. As various possible embodiments might be made of the mechanical features of the above invention and as the art herein described might be varied in various parts, all Without departing from the scope of the invention, it is to be understood that all matter hereinbefore set forth or shown in the accompanying drawing is to be interpreted as illustrative and not in a limiting sense.

What I claim is:

l. In apparatus for forming filaments within a stream of conning liquid and Without longitudinal tension, a forming tube having an inside diameter on the order of one-eighth of an inch, a conduit for supplying confining liquid to flow through said tube including a chamber of greater cross sectional area than said tube and opening into said tube, and merging with the tube around the entire perimeter of the entrance end of the tube, and an injector to inject a stream of filament forming liquid into the center of said stream of conning liquid, within said tube.

2. In apparatus for forming laments within through said tube, said means comprising, a cona Stream 0f COnning llqud and WithOl-lt 10Ilg1- 'duit including a chamber of greater cross sectudinal tension. a forming tube having an inside tional area than said tube and opening into said diameter on the order of one-eighth of an inch, frm-be, and injector means extending into said Chamber and positioned to inject a stream of la- 10 lence and merging into said tube around its entire ment forming liquid into the center of said stream perimeter ALBERT O. RYAN.

ing liquid to the tube Without turbulence and REFERENCES CITED merging into said tube around its entire perimeter. 15 The following references are of record in the 3. In apparatus for forming filaments Within me of this patent:

tudinal tension, a forming tube, having an inside UNITED STATES PATENT s diameter on the order of approximately one- Number Name Date sixteenth to one-fourth of an inch, means for 2o 838,758 Thiele Dec. 18, 1906 supplying a stream of confining liquid to ow 

